System and Method for Light Steel Frame Construction

ABSTRACT

A system and method for light steel frame construction which utilizes a single type of material for panels and fill to produce an affordable, thermally efficient, strong and durable building. The system and method for light steel frame construction generally includes a light steel frame to which is secured a plurality of outer block panels and inner block panels via fasteners. Each of the block panels is made of a porous concrete mix which is pre-cured and cut to form the rectangular panels. Gaps between the outer and inner block panels is filled with a fill material, the fill material being formed of a dry mix porous concrete which is mixed with water on-site and pumped into the gaps before being allowed to expand and cure. Adhesive materials may be applied to the panels to fill gaps and secure the panels to each other.

CROSS REFERENCE TO RELATED APPLICATIONS

I hereby claim benefit under Title 35, United States Code, Section 119(e) of U.S. provisional patent application Ser. No. 61/656,046 filed Jun. 6, 2012. The 61/656,046 application is currently pending. The 61/656,046 application is hereby incorporated by reference into this application.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable to this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a new construction method and more specifically it relates to a system and method for light steel frame construction which utilizes a single type of material for panels and fill to produce an affordable, thermally efficient, strong and durable building.

2. Description of the Related Art

Any discussion of the related art throughout the specification should in no way be considered as an admission that such related art is widely known or forms part of common general knowledge in the field.

Light steel frame construction is increasing in popularity due to its recognition as an advanced construction system which reduces building times and material costs. Disadvantages related to the use of light steel frames for construction are generally associated with the covering and fill materials used in the prior art to complete structures. Such existing materials have been known to result in poor fire performance, including structural weakening at high temperature, low acoustic proofing and higher costs related to thermal insulation due to multi-layer materials requirements.

Because of the inherent problems with the related art, there is a need for a new and improved system and method for light steel frame construction which utilizes a single type of material for panels and fill to produce an affordable, thermally efficient, strong and durable building.

BRIEF SUMMARY OF THE INVENTION

The invention generally relates to a new construction method and system which includes a light steel frame to which is secured a plurality of outer block panels and inner block panels via fasteners. Each of the block panels is made of a porous concrete mix which is pre-cured and cut to form the rectangular panels. Gaps between the outer and inner block panels is filled with a fill material, the fill material being formed of a dry mix porous concrete which is mixed with water on-site and pumped into the gaps before being allowed to expand and cure. Adhesive materials may be applied to the panels to fill gaps and secure the panels to each other. There has thus been outlined, rather broadly, some of the features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

FIG. 1 is an upper perspective view of an exemplary building constructed with the present invention.

FIG. 2 is an upper perspective view of the present invention illustrating a steel frame and panels being secured thereto.

FIG. 3 is an upper perspective cutaway view illustrating positioning of the steel frame, panels, fill material and finishing materials in a partially completed wall structure.

FIG. 4 is an upper perspective cutaway view illustrating positioning of the steel frame, panels, fill material and finishing materials in a completed wall structure.

FIG. 5 is a top sectional view of a wall structure constructed with the present invention.

FIG. 6 is a frontal view of a partially completed wall structure.

DETAILED DESCRIPTION OF THE INVENTION A. Overview.

Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 6 illustrate a system and method for light steel frame construction 10, which comprises a light steel frame 20 to which is secured a plurality of outer block panels 30 and inner block panels 40 via fasteners 36, 46. Each of the block panels 30, 40 is made of a porous concrete mix which is pre-cured and cut to form the rectangular panels 30, 40. Gaps between the outer and inner block panels 30, 40 is filled with a fill material 50, the fill material 50 being formed of a dry mix porous concrete which is mixed with water on-site and pumped into the gaps before being allowed to expand and cure. Adhesive materials 60 may be applied to the panels 30, 40 to fill gaps and secure the panels 30, 40 to each other.

It is appreciated that a wide range of building 11 types may be constructed using the systems and methods described herein. While the figures merely illustrate one embodiment of a building 11 constructed with the present invention, these exemplary illustrations should not be construed as limiting on the scope of the present invention. The system and methods described herein may be applied to numerous building sizes, shapes, and configurations. Further, the systems and methods described herein may be utilized in combination with other previously known construction systems and methods to construct a building 11 which is only partially embodied by the present invention.

B. Steel Frame.

The core element of the present is the use of customized light steel galvanized profile frames 20. The light steel frames 20 are comprised of horizontal and vertical supports 22, 26 which are interconnected or integrally formed to create one of a wide range of bearing structures such as walls, slabs, and other building elements. The thickness of the horizontal and vertical supports 22, 26 may vary, but will preferably range between 0.8 and 2 millimeters.

The horizontal supports 22 include an outer end 23 which faces outwardly from the completed building 11 and an inner end 24 which faces inwardly from the completed building 11. Similarly, the vertical supports 26 include an outer end 27 faces outwardly from the building 11 and an inner end 28 which faces inwardly from the building 11. The horizontal and vertical supports 22, 26 are clustered to form the interior frame 20 supporting lightweight cellular concrete walls as described herein.

The use of light steel frames 20 allows it to project force, with the light steel frame 20 carrying out the bearing role for the building 11 alone. The frame 20 is designed to bear all loads which will be present during the building's 11 life. The use of porous concrete panels 30, 40 and fill material 50 in connection with the frame 20 as described herein improves the strength and rigidity of the building 11, increases the durability of the steel frame 20, and adds a wide number of other advantages. The frame 20 is generally constructed on top of a concrete or other type of foundation 12 as shown in the figures when constructing the building 11. However, other configurations may be utilized and, in some embodiments, a foundation 12 may not be necessary.

C. Block Panels.

The present invention utilizes panels 30, 40 comprised of porous concrete which are secured to the outer and inner ends 23, 27, 24, 28 of the horizontal and vertical supports 22, 26 via fasteners 36, 46. The panels 30, 40 are generally comprised of both outer block panels 30 which are secured to the outer ends 23, 27 of the frame 20 and inner block panels 40 which are secured to the inner ends 24, 28 on the frame 20. Each of the panels 30, 40 includes an outer surface 31, 41 which faces away from the frame 20 and an inner surface 32, 42 which is secured against the outer ends 23, 27 of the frame 20. The panels 30, 40 are generally rectangular in shape, though other shapes and configurations may be utilized. The panels may be comprised of a range of densities, with preferable values ranging from 300 to 600 kg/m̂3 to fit general building requirements such as thermal insulation, acoustic proofing and the like.

The panels 30, 40 are preferably pre-fabricated off-site and delivered to the construction site in panel-form ready to be secured to the frame 20 either as-is or with only minor dimensional modifications. Thus, the panels 30, 40 are expanded and cured into their panel form off-site, as opposed to the fill material 50 described below, which is expanded and cured on-site within the building 11 construction.

Each of the panels 30, 40 is comprised of light weight cellular porous concrete which is formed into rectangular panels. Exemplary dimensions and configurations are listed herein for illustrative purposes only and should not be construed as limiting on the scope of the present invention. A first embodiment of the panels 30, 40 has a length of 1,190 mm, a width of 49 mm, a height of 590 mm, a dry density of 400 kg/m̂3 and a strength of 1.5 MPa. A second embodiment of the panels 30, 40 has a length of 1,190 mm, a width of 29 mm, a height of 590 mm, a dry density of 500 kg/m̂3 and a strength of 2.1 MPa. A third embodiment of the panels 30, 40 has a length of 1,190 mm, a width of 99 mm, a height of 590 mm, a dry density of 600 kg/m̂3 and a strength of 3.0 MPa. The selection of the type of panel 30, 40 may vary depending on the needs of the particular building 11 they are being used to construct.

Each of the panels 30, 40 includes apertures 34, 44 through which fasteners 36, 46 will extend to secure each panel 30, 40 to the frame 20. The panels 30, 40 may be constructed without discrete apertures 34, 44. In such an embodiment, the fasteners 36, 46 are driven directly through the panels 30, 40, thus creating apertures 34, 44 therein. In other embodiments, the panels 30, 40 may be secured to the frame 20 through methods other than fasteners 36, 46, such as the use of adhesives.

D. Fill Material.

The gap between outer and inner block panels 30, 40 will be filled with a fill material 50 comprising the same type of material which is used to form the panels 30, 40. Generally, the fill material 50 will be comprised of non-autoclave porous concrete which is expanded and cured on-site.

The fill material 50 is comprised of a dry porous concrete composition which is mixed with water on site. The fill material 50, after being mixed with water, is pumped between the block panels 30, 40 in heavy liquid form to fill the gaps therebetween. The expansion of the fill material 50 as it cures will act to fill any space penetrating into all small gaps and cracks which may be formed in the frame 20 or panels 30, 40.

Typically, the fill material 50 will expand in volume by two- or three-times within approximately 45 to 60 minutes, depending on the target dry density of the fill material. Preferred embodiments of the fill material 50 will include dry densities in the 200-400 kg/m̂3 range after expansion and curing, though higher or lower dry densities may be utilized for different applications.

The use of porous concrete for the panels 30, 40 and fill material 50 produces a number of benefits when compared with prior art systems. By way of example and without limitation, such benefits may include lower thermal conductivity (not more than 0.11 w/(mK) at 400 kg/m̂3 dry density), high sound-proof acoustic properties (40 dB), high compressive strength (up to 4.0N/mm̂2 at 600 kg/m̂3 dry density), high fire resistance, and low moisture absorption (3-4%). Further, the porous concrete may be easily sawed, nailed, or drilled with common tools. Additionally, the porous concrete does not include any active materials such as lyme and is completely non-reactive with water or air. Testing by the applicant has shown that building's 11 constructed using these materials may maintain durability for more than 100 years of summer-winter cycles.

E. Finishing Materials.

As best shown in FIG. 4, finishing materials 60, 62, 64 may be applied to the outer block panels 30 after they have been secured to the frame 20 and the fill material 50 has been applied. First, an adhesive material 60 may be applied across all panels 30 to fill gaps and close connections hermetically. While the panels 30 are secured to the frames 20 with fasteners 36, the adhesive material 60 may be applied to secure the panels 30 to each other by filling gaps therebetween. Various types of adhesive materials 60 may be utilized for such functionality.

Generally, a mesh material 62 will be positioned over the adhesive material 60 after it has been applied to the outer surface 31 of the outer block panels 30. Various types of mesh materials 62 may be utilized. In a preferred embodiment, the mesh material 62 will be comprised of fiberglass.

After application of the mesh material 62, a finishing lay 64 such as decorative plaster or other material may be applied over the mesh material 62. The decorative plaster 64 or other finishing lay will provide protection of the panels 30 from direct mechanical impacts, as well as increase the aesthetic appeal of the building 11. Finishing lays 64 such as cladding, siding and the like may also be utilized in some embodiments.

F. Fabrication Methods of Preferred Embodiment.

In use, a concrete foundation 12 is first formed on the construction site for the building 11. The frame 20 may then be constructed or placed on the foundation 12, comprised of a plurality of horizontal and vertical supports 22, 26 interconnected together to form the structure being constructed, such as a wall. The frame 20 may be constructed so as to support a large range of structures, from entire buildings to simple wall structures. As best shown in FIG. 2, with the frame 20 constructed and secured on the foundation 12, outer block panels 30 may be secured to the outer ends 23, 27 of the steel frame 20 and inner block panels 40 may be secured to the inner ends 24, 28 of the frame 20. The panels 30, 40 will preferably be secured to the frame 20 through use of fasteners 36, 46 such as fixing screws. The panels 30, 40 should also be carefully leveled after being secured to the frame 20. Any gaps between adjacent panels 30, 40 may be filled and hermetically closed with an adhesive material 60 which also secures the panels 30, 40 to each other.

A fill material 50 comprised of porous concrete dry mix will be mixed with water on-site and pumped between the gap which is formed between the respective outer block panels 30 and inner block panels 40 as shown in FIG. 3. The heavy liquid fill material 50 will be pumped before curing and allowed to cure and expand within the gaps; a process which typically takes 45 minutes to an hour, depending on the dry density of the fill material 50. After curing, the mesh 62 and any finishing lay 64 may be applied to complete the construction. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described above. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect. 

The invention claimed is:
 1. A wall structure for a building, comprising: a steel frame; a plurality of outer block panels secured to an outer end of said frame, each of said outer block panels being comprised of porous concrete; a plurality of inner block panels secured to an inner end of said frame, each of said inner block panels being comprised of porous concrete; and a fill material positioned in a gap formed between said outer block panels and said inner block panels, said fill material being comprised of porous concrete.
 2. The wall structure for a building of claim 1, wherein said steel frame is comprised of light weight steel.
 3. The wall structure for a building of claim 2, wherein said steel frame is comprised of horizontal supports and vertical supports.
 4. The wall structure for a building of claim 1, further comprising an adhesive material applied to said inner block panels and said outer block panels.
 5. The wall structure for a building of claim 4, further comprising a mesh material applied over said adhesive material of said outer block panels.
 6. The wall structure for a building of claim 5, further comprising a finishing material applied over said mesh material of said outer block panels.
 7. The wall structure for a building of claim 6, wherein said finishing material is comprised of a decorative plaster.
 8. The wall structure for a building of claim 6, wherein said finishing material is comprised of siding.
 9. The wall structure for a building of claim 6, wherein said finishing material is comprised of cladding.
 10. A method of constructing a wall for a building, comprising: providing a steel frame; securing a plurality of outer block panels to an outer end of said frame, each of said outer block panels being comprised of porous concrete; securing a plurality of inner block panels to an inner end of said frame, each of said inner block panels being comprised of porous concrete; filling a gap formed between said outer block panels and said inner block panels with a fill material, said fill material being comprised of a wet mix of porous concrete dry mix and water; and allowing said fill material to expand and cure within said gap.
 11. The wall structure for a building of claim 10, wherein said steel frame is comprised of light weight steel.
 12. The wall structure for a building of claim 11, wherein said steel frame is comprised of horizontal supports and vertical supports.
 13. The wall structure for a building of claim 10, further comprising the step of applying an adhesive material to said inner block panels and said outer block panels.
 14. The wall structure for a building of claim 13, further comprising the step of applying a mesh material over said adhesive material of said outer block panels.
 15. The wall structure for a building of claim 14, further comprising the step of applying a finishing material over said mesh material of said outer block panels.
 16. The wall structure for a building of claim 15, wherein said finishing material is comprised of a decorative plaster.
 17. The wall structure for a building of claim 16, wherein said finishing material is comprised of siding.
 18. The wall structure for a building of claim 16, wherein said finishing material is comprised of cladding.
 19. A wall structure for a building, comprising: a light-weight steel frame comprised of vertical supports and horizontal supports; a plurality of outer block panels secured to an outer end of said frame, each of said outer block panels being comprised of porous concrete; a plurality of inner block panels secured to an inner end of said frame, each of said inner block panels being comprised of porous concrete; an adhesive material applied to said inner block panels and said outer block panels; a mesh material applied over said adhesive material of said outer block panels; a finishing material applied over said mesh material of said outer block panels; and a fill material positioned in a gap formed between said outer block panels and said inner block panels, said fill material being comprised of porous concrete.
 20. The wall structure for a building of claim 19, wherein said finishing material is comprised of a decorative plaster. 